Low profile layered coil and cores for magnetic components

Abstract

A low profile magnetic component includes at least one coil layer defining a generally planar coil winding having a center area and a number of turns extending about the center area. A body encloses the coil layer, and is fabricated from one of a dielectric material and a magnetic material. A magnetic core material occupies at least the center area of the coil layer.

What is claimed is: 
     
       1. A magnetic component assembly comprising:
 at least one coil defining a coil winding having a center area and a number of turns extending about the center area; 
 a laminated body enclosing and embedding the coil, wherein the body is fabricated from one of a dielectric material and a magnetic material; and 
 a magnetic core material occupying at least the center area of the coil and a center area of the body, wherein the electrical and magnetic properties of the laminated body and the magnetic core material are different from one another, and wherein the magnetic core material is in surface engagement with at least a portion of the at least one coil. 
 
     
     
       2. The magnetic component assembly of  claim 1 , wherein the laminated body includes a first layer, the first layer including a core opening defining a receptacle for the introduction of the magnetic core material. 
     
     
       3. The magnetic component assembly of  claim 2 , wherein the laminated body further comprises a second layer, and both of the first and second layers comprise a core opening extending therethrough for the introduction of the magnetic core material. 
     
     
       4. The magnetic component assembly of  claim 3 , wherein the at least one coil includes a core opening extending therethrough in the center area. 
     
     
       5. The magnetic component assembly of  claim 4 , wherein the magnetic core material comprises a magnetic core element separately provided from the first and second layers, the magnetic core element extending through the core openings of the first and second magnetic sheets and the core opening of the at least one coil. 
     
     
       6. The magnetic component assembly of  claim 5 , wherein the magnetic core material is formed into one of a drum core and a rod core. 
     
     
       7. The magnetic component assembly of  claim 6 , wherein the laminated body comprises a coil portion fabricated from a first magnetic material and outer portions fabricated from a second magnetic material, the second magnetic material having different magnetic properties than the first magnetic material. 
     
     
       8. The magnetic component assembly of  claim 7 , wherein the magnetic core material is fabricated from a third magnetic material, the third magnetic material having different magnetic properties than the first and second magnetic materials. 
     
     
       9. The magnetic component assembly of  claim 6 , wherein the magnetic core material includes a center portion that is substantially entirely embedded between the outer portions of the magnetic body. 
     
     
       10. The magnetic component assembly of  claim 5 , wherein both of the first and second layers comprise a magnetic material, the magnetic core material of the first and second layers having different magnetic properties from the magnetic core element. 
     
     
       11. The component of  claim 1 , wherein the at least one coil comprises a double sided coil. 
     
     
       12. The magnetic component assembly of  claim 1 , wherein the at least coil comprises a flexible circuit coil. 
     
     
       13. The magnetic component assembly of  claim 12 , wherein the flexible circuit coil includes at least one termination pad. 
     
     
       14. The magnetic component assembly of  claim 1 , wherein the at least coil comprises a plurality of spaced apart coils. 
     
     
       15. The magnetic component assembly of  claim 14 , wherein the spaced apart coils are connected by at least one via. 
     
     
       16. The magnetic component assembly of  claim 1 , wherein the laminated body includes a first layer, the first layer comprising a polymer-based film. 
     
     
       17. The magnetic component assembly of  claim 16 , wherein the polymer-based film is a polyimide film. 
     
     
       18. The magnetic component assembly of  claim 1 , wherein the laminated body includes a first layer, the first layer comprising a liquid crystal polymer. 
     
     
       19. The magnetic component assembly of  claim 1 , wherein the at least one coil comprises an electroformed coil winding formed independently of the first and second layers. 
     
     
       20. The magnetic component assembly of  claim 1 , wherein the laminated body includes a first layer, the first layer comprising a moldable magnetic material. 
     
     
       21. The magnetic component assembly of  claim 20 , wherein the moldable magnetic material comprises at least one of Ferrite particles, Iron (Fe) particles, Sendust (Fe—Si—Al) particles, MPP (Ni—Mo—Fe) particles, HighFlux (Ni—Fe) particles, Megaflux (Fe—Si Alloy) particles, iron-based amorphous powder particles, cobalt-based amorphous powder particles, and equivalents and combinations thereof. 
     
     
       22. The magnetic component assembly of  claim 21 , wherein the laminated body includes a second layer, the second layer comprising a moldable magnetic material. 
     
     
       23. The magnetic component assembly of  claim 22 , wherein the moldable magnetic material of the second layer has different magnetic properties from the moldable magnetic material of the first layer. 
     
     
       24. The magnetic component assembly of  claim 1 , further comprising surface mount terminations. 
     
     
       25. The magnetic component assembly of  claim 1 , wherein the component is an inductor. 
     
     
       26. The magnetic component assembly of  claim 1 , wherein the inductor is a miniaturized inductor. 
     
     
       27. The magnetic component assembly of  claim 1 , wherein the laminated body comprises stacked magnetic layers, and wherein the magnetic core material is provided integrally with the magnetic layers. 
     
     
       28. The magnetic component assembly of  claim 1 , wherein the laminated body comprises a plurality of flexible layers of materials joined in surface contact with one another. 
     
     
       29. The magnetic component assembly of  claim 28 , wherein the plurality of flexible layers comprises a plurality of flexible magnetic sheets. 
     
     
       30. A magnetic component assembly comprising:
 at least one coil defining a coil winding having a center area and a number of turns extending about the center area; 
 a laminated magnetic body enclosing and embedding the coil, wherein the laminated magnetic body is fabricated from a first magnetic material and a second magnetic material having different properties; and 
 a magnetic core material occupying at least the center area of the coil and a center area of the body, wherein the magnetic core material is fabricated from a third magnetic material having different properties from the first and second magnetic materials.